U.S. patent application number 14/112166 was filed with the patent office on 2014-02-06 for glass fiberboard and production method therefor.
This patent application is currently assigned to LG Hausys,LTd. The applicant listed for this patent is Suk Jang, Seong-Moon Jung, Eun-Joo Kim, Myung Lee. Invention is credited to Suk Jang, Seong-Moon Jung, Eun-Joo Kim, Myung Lee.
Application Number | 20140034868 14/112166 |
Document ID | / |
Family ID | 47139829 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140034868 |
Kind Code |
A1 |
Lee; Myung ; et al. |
February 6, 2014 |
GLASS FIBERBOARD AND PRODUCTION METHOD THEREFOR
Abstract
The present invention relates to a glass fiberboard and to a
production method therefor, and more specifically, to technology
for providing a glass fiberboard for vacuum heat insulation and a
production method therefor, which have outstanding initial heat
insulation performance and economic advantages through application
of an optimized inorganic binder.
Inventors: |
Lee; Myung; (Hwaseong-si,
KR) ; Jung; Seong-Moon; (Daejeon, KR) ; Jang;
Suk; (Seoul, KR) ; Kim; Eun-Joo; (Uiwang-si,
KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lee; Myung
Jung; Seong-Moon
Jang; Suk
Kim; Eun-Joo |
Hwaseong-si
Daejeon
Seoul
Uiwang-si |
|
KR
KR
KR
KR |
|
|
Assignee: |
LG Hausys,LTd
|
Family ID: |
47139829 |
Appl. No.: |
14/112166 |
Filed: |
May 11, 2012 |
PCT Filed: |
May 11, 2012 |
PCT NO: |
PCT/KR2012/003699 |
371 Date: |
October 16, 2013 |
Current U.S.
Class: |
252/62 ;
264/319 |
Current CPC
Class: |
C04B 30/02 20130101;
C04B 14/42 20130101; C04B 30/02 20130101; E04B 1/78 20130101; C03C
25/42 20130101; C04B 40/0259 20130101; C04B 40/0259 20130101; C04B
40/0263 20130101; C04B 14/42 20130101; C04B 28/005 20130101; C04B
40/0263 20130101; C04B 14/42 20130101; C04B 14/42 20130101; C04B
28/005 20130101; C04B 20/1066 20130101; B29D 99/001 20130101 |
Class at
Publication: |
252/62 ;
264/319 |
International
Class: |
E04B 1/78 20060101
E04B001/78; B29D 99/00 20060101 B29D099/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 12, 2011 |
KR |
1020110044629 |
Claims
1. A glass fiberboard comprising: glass fibers and an inorganic
binder, wherein the inorganic binder comprises an aluminum compound
prepared by neutralization of an aluminum-containing acidic
solution and a basic solution.
2. The glass fiberboard according to claim 1, wherein the
aluminum-containing acidic solution is aluminum sulfate.
3. The glass fiberboard according to claim 1, wherein the basic
solution is sodium hydroxide.
4. The glass fiberboard according to claim 1, wherein the aluminum
compound is aluminum hydroxide.
5. The glass fiberboard according to claim 1, wherein a dried
product of the aluminum compound is aluminum oxide.
6. (canceled)
7. A method for producing a glass fiberboard, comprising: preparing
a mixture solution by stifling glass fibers and an inorganic binder
solution; obtaining an extract by removing water from the mixture
solution; and compressing and drying the extract.
8. The method for producing a glass fiberboard according to claim
7, wherein the inorganic binder solution comprises a mixture of an
aluminum-containing acidic solution and a basic solution.
9. The method for producing a glass fiberboard according to claim
8, wherein the aluminum-containing acidic solution is aluminum
sulfate.
10. The method for producing a glass fiberboard according to claim
8, wherein the basic solution is sodium hydroxide.
11. The method for producing a glass fiberboard according to claim
8, wherein the mixture comprises an aluminum compound.
12. The method for producing a glass fiberboard according to claim
11, wherein the aluminum compound is aluminum hydroxide.
13. The method for producing a glass fiberboard according to claim
11, wherein a dried product of the aluminum compound is aluminum
oxide.
14.-18. (canceled)
19. A method for producing a glass fiberboard, comprising:
preparing glass fibers; depositing an inorganic binder solution to
the glass fibers; and compressing and drying the glass fibers
deposited with the inorganic binder solution.
20. The method for producing a glass fiberboard according to claim
19, wherein the inorganic binder solution comprises a mixture of an
aluminum-containing acidic solution and a basic solution.
21. The method for producing a glass fiberboard according to claim
20, wherein the aluminum-containing acidic solution is aluminum
sulfate.
22. The method for producing a glass fiberboard according to claim
20, wherein the basic solution is sodium hydroxide.
23. The method for producing a glass fiberboard according to claim
20, wherein the mixture comprises an aluminum compound.
24. The method for producing a glass fiberboard according to claim
23, wherein the aluminum compound is aluminum hydroxide.
25. The method for producing a glass fiberboard according to claim
23, wherein a dried product of the aluminum compound is aluminum
oxide.
26.-29. (canceled)
Description
TECHNICAL FIELD
[0001] The present invention relates to glass fiberboards and a
production method therefor, and more particularly, to a technology
for providing a glass fiberboard for vacuum heat insulation, which
has outstanding initial heat insulation performance and economic
advantages through application of an optimized inorganic binder,
and a production method therefor.
BACKGROUND ART
[0002] Glass fiberboards for vacuum heat insulation have excellent
long-term durability of 15 years or more and excellent initial
thermal conductivity of 3.0 mW/mk or less at a size of
600.times.600 mm
[0003] Generally, glass fiberboards are produced by mixing
micro-glass fibers and general glass fibers in a ratio of 6:4 to
9:1, stirring in a solution of pH 2.about.4, and drying the mixture
in the form of a board. Upon stirring, the micro-glass fibers are
twisted, thereby facilitating production of the glass fiberboard
while providing excellent heat insulation performance.
[0004] On the other hand, micro-glass fibers having a diameter of
1.about.3 .mu.m are produced by a flame process, which cause
environmental pollution and often suffers poor quality causing
significant increase in manufacturing costs. Due to such
disadvantages, the production of micro-glass fibers is only allowed
in some countries, and regulations concerning treatment of glass
fibers having a diameter of 4 .mu.m or less are enforced in Europe
due to concerns regarding human heath.
[0005] Therefore, there is a need for development of a core
material for vacuum heat insulation with standardized glass fibers
having a diameter of 4 .mu.m or more.
[0006] To produce a board using standardized glass fibers, a binder
is used. Glass fibers having a diameter of 4 .mu.m or more have a
linear shape and thus do not entail a twisting phenomenon unlike
micro-glass fibers.
[0007] In use of a general inorganic binder, movement of moisture
causes the binder to move in the course of drying, whereby only the
surface can be cured, thereby causing deterioration in heat
insulation performance.
[0008] Therefore, there is a need for the provision of a glass
fiberboard through application of an optimized inorganic binder to
standardized glass fibers such that the binder and the glass fibers
can be uniformly distributed even after drying.
DISCLOSURE
Technical Problem
[0009] It is an aspect of the present invention to provide a glass
fiberboard for vacuum heat insulation, in which an inorganic binder
and glass fibers are uniformly distributed even after drying
through application of an optimized inorganic binder to
standardized glass fibers so as to provide excellent initial heat
insulation performance and economic advantages, and a production
method therefor.
Technical Solution
[0010] In accordance with one aspect of the invention, a glass
fiberboard includes glass fibers and an inorganic binder, wherein
the inorganic binder includes an aluminum compound prepared by
neutralization of an aluminum-containing acidic solution and a
basic solution.
[0011] In accordance with another aspect of the invention, a method
for producing a glass fiberboard includes: preparing a mixture
solution by stirring glass fibers and an inorganic binder solution;
obtaining an extract by removing water from the mixture solution;
and compressing and drying the extract.
[0012] In accordance with a further aspect of the invention, a
method for producing a glass fiberboard includes: preparing glass
fibers; depositing an inorganic binder solution to the glass
fibers; and compressing and drying the glass fibers deposited with
the inorganic binder solution.
Advantageous Effects
[0013] The glass fiberboard according to embodiments of the
invention employs standardized glass fibers, thereby providing
excellent productivity and economic advantages without generating
environmental pollution.
[0014] In addition, the glass fiberboards according to the
embodiments employ an optimized inorganic binder to allow the glass
fibers and the binder to be uniformly distributed in the board,
thereby providing excellent heat insulation performance.
DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a flowchart of a method for producing a glass
fiberboard according to one embodiment of the present
invention.
[0016] FIG. 2 is a flowchart of a method for producing a glass
fiberboard according to another embodiment of the present
invention.
[0017] FIG. 3 is a graph depicting initial thermal conductivity of
glass fiberboards prepared in inventive examples and comparative
examples.
[0018] FIG. 4 is a scanning electron micrograph (SEM) of a glass
fiberboard prepared in a comparative example.
[0019] FIG. 5(a) is an SEM micrograph of a glass fiberboard
prepared in one example, and FIG. 5(b) is a partially enlarged
view.
BEST MODE
[0020] The above and other aspects, features, and advantages of the
present invention will become apparent from the detailed
description of the following embodiments in conjunction with the
accompanying drawings. It should be understood that the present
invention is not limited to the following embodiments and may be
embodied in different ways, and that the embodiments are provided
for complete disclosure and thorough understanding of the invention
by those skilled in the art. The scope of the present invention is
defined only by the claims. Like components will be denoted by like
reference numerals throughout the specification.
[0021] Now, exemplary embodiments of the invention will be
described in detail with reference to the accompanying
drawings.
[0022] Glass fiberboard
[0023] According to the invention, a glass fiberboard includes
glass fibers and an inorganic binder, wherein the inorganic binder
includes an aluminum compound prepared by neutralization of an
aluminum-containing acidic solution and a basic solution.
[0024] Here, although any glass fibers may be used without
limitation so long as the glass fibers can be used as core
materials for vacuum thermal insulation, standardized glass fibers,
which can be easily produced without causing environmental
pollution are advantageously used. More specifically, glass fibers
having a diameter of 6 .mu.m or less are used in term of easy
production.
[0025] The inorganic binder includes an aluminum compound, which is
prepared through neutralization of an aluminum-containing acidic
solution and a basic solution.
[0026] Here, the aluminum-containing acidic solution may be
aluminum sulfate, and the basic solution may be sodium
hydroxide.
[0027] The basic solution generates an aluminum compound (salt)
through reaction with the aluminum-containing acidic solution, and
the aluminum compound (salt) serves as a binder for the glass
fibers.
[0028] That is, in the present invention, the aluminum compound
produced through neutralization of the basic solution and the
aluminum-containing acidic solution is used as the inorganic
binder. Here, the aluminum compound (salt) may be aluminum
hydroxide.
[0029] When the aluminum-containing acidic solution is aluminum
sulfate and the basic solution is sodium hydroxide, the aluminum
compound (salt) may be produced according to the following reaction
formula.
Al.sub.2(SO.sub.4).sub.3(s)+6NaOH(aq).fwdarw.2Al(OH).sub.3(s)+6Na.sup.+(-
aq)+3SO.sub.4.sup.2-(aq)
[0030] The aluminum compound (salt) produced by neutralization is
not displaced by movement of water in the course of drying, and can
be uniformly distributed between the glass fibers, thereby
providing excellent performance as a binder.
[0031] A dried product of the aluminum compound (salt) is aluminum
oxide and is produced according to the following reaction
formula.
2Al(OH).sub.3(s).fwdarw.Al.sub.2O.sub.3(s)+3H.sub.2O(g)
[0032] Aluminum oxide produced as the dried product serves as a
binder which allows standardized glass fibers having a diameter of
4.about.6 .mu.m to be efficiently agglomerated while being
uniformly distributed between the glass fibers.
[0033] Method for Producing Glass Fiberboard
[0034] As shown in FIG. 1, a method of producing a glass fiberboard
according to one embodiment includes preparing a mixture solution
by stirring glass fibers and an inorganic binder solution (S100);
obtaining an extract by removing water from the mixture solution
(S110); and compressing and drying the extract (S120).
[0035] First, the mixture solution is prepared by stirring the
glass fibers and the inorganic binder solution (S100).
[0036] Although any glass fibers may be used without limitation so
long as the glass fibers can be used as core materials for vacuum
thermal insulation, standardized glass fibers, which can be easily
produced without generating environmental pollution are
advantageously used. Advantageously, glass fibers having a diameter
of 6 .mu.m or less are used in term of easy production.
[0037] The inorganic binder solution is prepared by mixing the
inorganic binder with water. The inorganic binder is described
above and a description thereof will not be repeated.
[0038] The inorganic binder may be present in an amount of 0.1% by
weight (wt %) to 1 wt % based on the total weight of the inorganic
binder solution. When the amount of the inorganic binder is less
than 0.1 wt %, there can be a problem of undesirable board
strength, and when the amount of the inorganic binder exceeds 1 wt
%, the inorganic binder can cause increase in thermal
conductivity.
[0039] The glass fibers may be present in an amount of 0.5 wt % to
1 wt % based on the total weight of the mixture solution. This
content of the glass fibers is set to secure uniform dispersion of
the glass fibers during stirring.
[0040] There is no restriction as to the stirring rate, and the
mixture solution is prepared by sufficiently stirring the glass
fibers and the inorganic binder to be uniformly mixed with each
other.
[0041] Then, an extract is prepared by removing water from the
mixture solution (S110).
[0042] To remove water from the mixture solution, a sieve is used.
When the mixture solution is passed through the sieve, water passes
through the sieve, and only the extract, which is the mixture of
the glass fibers and the binder, remains in the sieve.
[0043] Then, the extract is subjected to vacuum suctioning to
remove the remaining moisture from the extract to reduce drying
time.
[0044] Next, the extract is subjected to compression and drying,
thereby providing a completed glass fiberboard (S120).
[0045] Here, compression of the extract may be carried out at a
pressure of 2.0 kg/cm.sup.2 to 2.4 kg/cm.sup.2, and drying may be
carried out at a temperature of 250.degree. C. to 300.degree. C.
for 10.about.5 minutes.
[0046] If the compression pressure is less than 2.0 kg/cm.sup.2,
the glass fibers can be arranged not to be perpendicular to a
thickness direction, and if the compression pressure exceeds 2.4
kg/cm.sup.2, the physical properties of the glass fibers can be
degraded due to excessive compression. If the drying temperature is
less than 250.degree. C., the glass fibers can be insufficiently
dried, and if the drying temperature exceeds 300.degree. C., the
physical properties of the glass fibers can be degraded.
[0047] If the drying time is less than 10 minutes, the glass fibers
can be insufficiently dried, and if the drying time exceeds 15
minutes, there is a problem of deterioration in drying effects as
compared with the drying time since the extract can be excessively
dried in the course of drying.
[0048] Referring to FIG. 2, a method of producing a glass
fiberboard according to another embodiment of the invention
includes: preparing glass fibers (S200); depositing an inorganic
binder solution to the glass fibers (S210); and compressing and
drying the glass fibers deposited with the inorganic binder
solution (S220).
[0049] In the operation of depositing the inorganic binder solution
in the prepared glass fibers (S210), deposition of the inorganic
binder solution may be advantageously performed by mixing the
aluminum-containing acidic solution with the basic solution and
spraying the mixture, without being limited thereto.
[0050] Other operations of this method according to this embodiment
are the same as those of the production method according to the
above embodiment, and a detailed description thereof will thus be
omitted.
[0051] Next, the present invention will be described in detail with
reference to some specific examples.
EXAMPLE AND COMPARATIVE EXAMPLE
Production of Glass Fiberboard
Example 1
[0052] Prepared glass fibers are obtained by mixing glass fibers
having a diameter of 4 .mu.m and glass fibers having a diameter of
6 .mu.m in a ratio of 7:3. Then, 3 g of a sodium hydroxide and
aluminum sulfate mixture was added to 1 L of water to prepare a
binder solution. The prepared glass fibers were added to the binder
solution to be present in an amount of 1 wt % based on the total
weight of the binder solution, followed by stirring at 300 rpm
using a stirrer. The mixture was passed through a sieve to remove
water from the mixture to produce an extract, which in turn was
subjected to vacuum suctioning and compression at a pressure of 2.0
kg/cm.sup.2 for 30 seconds. Then, the compressed extract was dried
at 250.degree. C. for 10 minutes, thereby producing a glass
fiberboard.
Example 2
[0053] A glass fiberboard was produced in the same manner as in
Example 1 except that a binder solution was prepared by adding 1.5
g of a sodium hydroxide and aluminum sulfate mixture to 1 L of
water.
Example 3
[0054] A glass fiberboard was produced in the same manner as in
Example 1 except that a binder solution was prepared by adding 5 g
of a sodium hydroxide and aluminum sulfate mixture to 1 L of
water.
Example 4
[0055] A glass fiberboard was produced in the same manner as in
Example 1 except that a binder solution was prepared by adding 10 g
of a sodium hydroxide and aluminum sulfate mixture to 1 L of
water
Example 5
[0056] A glass fiberboard was produced in the same manner as in
Example 1 except that a binder solution was prepared by adding 20 g
of a sodium hydroxide and aluminum sulfate mixture to 1 L of
water.
Comparative Example 1
[0057] A glass fiberboard was produced in the same manner as in
Example 1 except that the sodium hydroxide and aluminum sulfate
mixture was not used.
Comparative Example 2
[0058] A glass fiberboard was produced by a typical method using a
common silica sol as the binder.
Comparative Example 3
[0059] A mixture obtained by mixing a resol type phenolic resin and
a urea resin in a mass ratio of 80:20 was dissolved in water to
prepare a resin solution (solid content: 40%). 100 parts by weight
of the resin solution, 3 parts by weight of an aqueous silica sol,
2 parts by weight of ammonium sulfate, and 2 parts by weight of
heavy oil emulsion in terms of solid content were mixed and
adjusted to a pH of 8.0 with 25% ammonia solution, followed by
diluting the mixture with water to achieve a solid content of 18%,
thereby preparing an aqueous binder for inorganic fibers. Other
processes were carried out in the same manner as in Example 1 to
produce a glass fiberboard.
[0060] Evaluation
[0061] 1. Initial Thermal Conductivity
[0062] (1) Thermal Conductivity According to the Content of Sodium
Hydroxide and Aluminum Sulfate
[0063] The initial heat conductivities of the glass fiberboards
prepared in Examples 1 to 5 and Comparative Example 1 were
measured.
[0064] Measurement results are shown in FIG. 3. From this, it can
be seen that the glass fiberboards exhibited desirable initial
thermal conductivity when 1.5.about.5 g of the sodium hydroxide and
aluminum sulfate mixture was added. In particular, the glass
fiberboard prepared in Example 1 had the lowest initial thermal
conductivity, thereby providing excellent heat insulation
performance.
[0065] (2) Thermal Conductivity in Comparative Examples 2 and 3
[0066] The initial heat conductivities of the glass fiberboards
prepared in Comparative Examples 2 and 3 were measured.
[0067] Measurement results are shown in Table 1.
TABLE-US-00001 TABLE 1 Thermal conductivity Comparative Example 2
5.24 mW/mK Comparative Example 3 4.97 mW/mK
[0068] 2. EDS Analysis
[0069] Through composition analysis of the glass fiberboards
prepared in Examples 3 and 4 and Comparative Example 1, the binder
content of the glass fibers was obtained. For this purpose,
composition analysis was performed on two points of each prepared
glass fiberboard specimen, and the binder content was obtained
based on an average thereof. Results are shown in Table 2.
TABLE-US-00002 TABLE 2 Comparative Element Example 1(%) Example
3(%) Example 4(%) O 47.46 50.72 51.98 Na 9.62 8.82 10.02 Mg 1.16
1.16 1.16 Al 1.92 2.69 3.47 Si 31.36 30.62 27.88 Ca 8.49 5.99 5.48
Binder content 0 1.47 2.94
[0070] 3. Verification of Binder Through SEM Analysis
[0071] SEM analysis was performed to ascertain uniform distribution
of the binder in the glass fibers.
[0072] FIG. 4 shows a scanning electronic micrograph (SEM) of the
glass fiberboard prepared in Comparative Example 1, and FIG. 5
shows an SEM micrograph of the glass fiberboard prepared in Example
1.
[0073] From FIG. 4 and FIG. 5, it can be ascertained that the glass
fiberboards of the inventive example include uniformly distributed
aluminum oxide on surfaces of the glass fibers.
[0074] Although some embodiments have been described herein, it
will be understood by those skilled in the art that various
modifications, changes, alterations and equivalent embodiments can
be made without departing from the scope of the present invention.
Therefore, the scope of the present invention is not limited by the
above embodiments and should be defined by the accompanying claims
and equivalents thereof.
[0075] Although the present invention has been described with
reference to some embodiments and the accompanying drawings, it
will be understood by those skilled in the art that these
embodiments are provided for illustrative purposes only, and
various modifications, changes, alterations and equivalent
embodiments can be made without departing from the scope of the
present invention. Therefore, the scope and sprit of the present
invention should be defined only by the accompanying claims and
equivalents thereof.
* * * * *